Discrete packaging adapter for connector

ABSTRACT

An adapter has two conductors each with a U-shaped bend forming upper longer legs and lower shorter legs. The conductors face each other with the longer legs linearly aligned with each other and the shorter legs aligned with each other, thereby forming a first gap between the longer legs and a second gap between the shorter legs. The first gap is substantially smaller than the second gap, so that an electrical package can be placed across the first gap to contact the two upper longer legs, while the two shorter legs are spaced further apart to span a larger gap between conductors of a connector. Thus, the adapter enables the electrical package to be connected to conductors having a gap that is larger than the electrical package.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to a connector adapter that receives anelectronic component. More particularly, the present invention relatesto a connector adapter package that receives a discrete electroniccomponent and connects the discrete component to contacts intended forlarger sized components.

Background of the Invention

FIG. 1 shows a traditional backplane construction having threesubstrates or printed circuit boards (PCB), for instance whereby twodaughtercards PCBs 30, 40 are connected to each other across a backplanePCB 50. The daughtercards 30 are each electronically connected to thebackplane 50 by a respective orthogonal electrical connector 20 ₁, 20 ₂,each having an electronic component 32, 42 such as a processing device(e.g., transmitter, receiver, processor, etc.). In a basic illustrativeembodiment, the processing device 32 communicates with the processingdevice 42 by transmitting a signal along a signal path. Signals are sentby the processing device 32 across the board traces and the vias 34 ₁,34 ₂, through the board 30 to the vias 38 ₁, 38 ₂ and to the firstconnector 20 ₁. The signals then travel from the first connector 20 ₁through the backplane vias 52 ₁, 52 ₂, and then the second connectorvias 54 ₁, 54 ₂ and to the second connector 20 ₂. The signals thencontinue to travel from the second connector 20 ₂, through thedaughtercard vias 48 ₁, 48 ₂ to the processing device vias 44 ₁, 44 ₂and to the processing device 42.

As discussed in U.S. Pat. No. 7,285,018 to Kenny which is herebyincorporated by reference, there is often the need to use a passivecircuit element in the signal path. These passive circuit elements, suchas capacitors, inductors, and resistors can be used to (a) block orreduce the flow of direct current caused by potential differencesbetween electronic components 32, 42, (b) provide desired filteringcharacteristics, and/or (c) reduce data transmission losses. To addressthese issues, passive circuit elements 10 ₁, 10 ₂ have been addeddirectly to the board 30 and/or board 40 respectively, as shown in FIG.1A, and capacitors 10 ₂ are sometimes located as close as possible tothe pins of the receiver 42 (as opposed to on the transmit side in theembodiment shown in FIG. 1A).

Surface-mount technology (SMT) is a method for producing electroniccircuits in which electronic surface-mounted devices (SMDs) orsurface-mounted components (SMCs) are mounted or placed directly ontothe surface of printed circuit boards (PCBs). The SMDs or SMCs are madein standardized package shapes and sizes. For instance, a package size“0402” device has rectangular size with a width of 0.50 mm, a height of0.50 mm, and a length of 1.00 mm; a “0201” device is half that size,with a width of 0.25 mm, height of 0.25 mm, and a length of 0.50 mm; anda “01005” device has a width of 0.12 mm, height of 0.12 mm, and lengthof 0.25 mm. The size of the device can affect the value and applicationof the package. For instance a “0402” capacitor can have a capacitanceof 100 Picofarads, whereas a 01005 capacitor has a capacitance of 50Picofarads.

An example of a standard discrete passive device 10 for a capacitor(which can be used for the capacitors 10 ₁, 10 ₂ of FIG. 1A) is shown inFIG. 1B. The discrete device (or package) 10 includes two end terminalsor members 12 ₁, 12 ₂ and a center body member 14 extending from one endmember 12 ₁ to the other end member 12 ₂. The capacitor package 10 isshown in block form and the end members 12 ₁, 12 ₂ enlarged (withrespect to the body) for ease of illustration, with the package 10having a generally rectangular elongated shape. The center body member14 is rectangular, and the end members 12 ₁, 12 ₂ are rectangular, witha longitudinal axis of the center body member 14 extending substantiallyperpendicular to the longitudinal axis of the end members 12 ₁, 12 ₂.Thus, the center body 14 has two opposite ends, and an end terminal 12is located at each of those ends. The end members 12 ₁, 12 ₂ are longerthan the width of the center body member 14, as shown. The end members12 ₁, 12 ₂ each have a top surface or face 13, side surfaces or faces15, a bottom surface or face 16, and an end surface or face 18. Each ofthe package sizes, 0402, 0201 and 01005, have a similar shape, and onlydiffer in size. It should be recognized, however, that any suitableshape and size can be provided, and for instance the package 10 need notbe rectangular in shape and the end members 12 ₁, 12 ₂ need not be widerthan the center body member 14.

Referring to FIG. 1A, when the passive circuit element 10 ₁, 10 ₂ arelocated on the board 30, 40, it takes up precious space on the boardsurface and contributes to SDD21 signal attenuation. In addition, thepassive circuit vias 35 ₁, 35 ₂, and vias 45 ₁, 45 ₂ respectively, cancreate capacitance and reflection in the through holes, reflections ofthe via stubs, skews caused by the lack of routing space, platedthrough-hole defects (voids and cracks), back drillingerrors/tolerances, localized cross talk between vias and traces, anduses valuable switch card space in high traffic areas.

One technique for addressing those issues is disclosed in U.S. Pat. No.8,591,257 to Girard et al., which is incorporated herein by reference.In that patent, the passive circuit packages are placed in the connectorwafer 20 ₁ and/or 20 ₂, rather than on the board 30, 40 so that thecapacitors 10 ₁, 10 ₂ are not needed. As illustrated in the wafer 20 ofFIGS. 2A and 2B, openings 22 are provided in the wafer housing (overmold 23) to expose a conductor 24 of the lead frame. A gap 26 is createdin the conductor 24, resulting in two conductor ends 24 a, 24 b, and thepackage 10 is placed across the gap to connect with the conductor ends24 a, 24 b. The bottom face 16 of the end members 12 ₁, 12 ₂ are adheredto the top surface of the exposed ends 24 a, 24 b of the conductor 24,such as by an adhesive or solder. As best shown in FIG. 2B, the wafer 20includes a top layer 27 of the over mold 23, a bottom layer 28 of theover mold 23, and the conductors 24 a, 24 b of the lead frame positionedthere between. The opening 22 is provided in the top layer 27 and thebottom layer 28 that exposes the conductor leads 24 a, 24 b. The package10 is positioned inside the opening 22 in the top layer 27 to connectwith the two conductors 24 a, 24 b of the lead frame. Packages are alsoshown in the connector of U.S. Pat. No. 8,382,524 to Khilchenko, whichis hereby incorporated by reference.

The conductor 24 has a thickness T and the gap 26 has a width W. Thewidth W of the gap 26 can be larger than or equal to the thickness T ofthe conductor 24. However, the size of the gap 26 is dependent on thethickness T of the conductor 24, because the gap 26 cannot be reliablymade smaller than the thickness T of the conductor 24. Thus, the width Wof the gap 26 is only made larger or equal to the thickness T of theconductor 24. And the thickness T of the conductor 24 can only bereduced to a certain extent, based on a number of factors such as:characteristic impedance Zo targets, progressive stamping die toolcapabilities, normal force targets for beam design/beam strength due tonormal force or spring force (e.g., minimum end of life normal force of40 grams) for the separable mating interfaces, coined features needs andstrength requirements such as those tied to press fit eye of the needledynamic sections, resistance to damage, shape change, location changesduring manufacturing processes, such as but not limited to molding,stamping, reeling, plating, assembly and handling.

Accordingly, the gap 26 has to be equal to or larger than the thicknessT of the conductor 24, which means that the package 10 has to be largeenough to span the gap 26. Consequently, the package (such as acapacitor) 10 of FIGS. 1-2 may be unable to electrically connect to theleads 24 a, 24 b of the lead frame if the package is too small to spanthe width W of the gap 26. More specifically, the gap 26 may be toolarge for the smaller package such as the 0201-sized package 5 to spanthe gap 24 and connect with the conductors 24 a, 24 b, such that onlythe larger package such as the 0402-sized package 10 (FIG. 1B) can beutilized. Thus, there is a need for a wafer 20 configured toelectrically connect packages (such as capacitors) smaller than thepackage 10 of FIG. 1B between the leads 24 a, 24 b of the lead frame.

Another technique to address the issues faced by having a passivecircuit device package 10 on the boards 30, 40 is shown in U.S. Pat. No.8,241,067 to Girard, Jr. et al., which is hereby incorporated byreference. In that patent, the capacitor is located on the board closeto one of the signal conductor tails of the connector. The capacitordoes not have its own vias (as in FIG. 1 above), but instead shares avia with that signal conductor tail.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the invention to increase the density ofconductor leads and packages and the speed of the signals carried onthose conductor leads. Due to Transmit/Receive (Tx/Rx) systemconstraints, however, one (or both) of the connector(s) of FIGS. 1-2 mayneed a capacitor with specific properties (e.g., 100 Picofarads ofcapacitance), and at present utilize a 0402 size package. Capacitance isrelated to package size, materials used and internal design. Eachcapacitors style and body sizes will deliver a minimum capacitance. Thelarger size of the 0402 package hinders the ability to increase thedensity of the connector. In addition, the ability to separate traces tosolder in a smaller device is limited by material thickness of the leadframes. This part of lead frame design is related to both electrical andmechanical requirements such as co-planar coupling of differentialpairs, beam design for mating interface and press fit dynamic sectionrequirements.

It is a further object of the invention to provide an adapter that canconnect multiple packages in parallel and/or in series. It is still afurther object of the invention to provide an adapter that can enable apackage to connect with conductor leads that are spaced apart by adistance that is greater than the size of the package.

In accordance with these and other objectives, an adapter is providedwith two conductors, each with a U-shaped bend forming upper longer legsand lower shorter legs. The conductors face each other with the longerlegs aligned with each other and the shorter legs aligned with eachother, thereby creating first gap between the longer legs and a secondgap between the shorter legs. The first gap is substantially smallerthan the second gap, so that an electrical package can be placed acrossthe first gap to contact the two upper longer legs, while the twoshorter legs are spaced further apart to span a larger gap betweenconductors of a connector. Thus, the adapter enables the electricalpackage to be connected to conductors having a gap that is larger thanthe electrical package.

These and other objects of the invention, as well as many of theintended advantages thereof, will become more readily apparent whenreference is made to the following description, taken in conjunctionwith the accompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1A shows a conventional backplane with 2 daughter cardconstruction;

FIG. 1B shows a capacitor package in accordance with the prior art;

FIGS. 2A, 2B show the capacitor package of FIG. 1 fitted in a wafer;

FIG. 3A is a perspective cross-section of the capacitor package of FIG.1 in an adapter in accordance with an embodiment of the invention;

FIG. 3B is a top view of the adapter of FIG. 3A without encapsulant, andcompared to the size of a standard 0402 capacitor package;

FIG. 3C is a bottom view of the adapter of FIG. 3A;

FIG. 4A shows an adapter configured to receive two capacitor packages;

FIG. 4B is the adapter of FIG. 4A with the encapsulant removed;

FIG. 4C is a bottom view of the adapter of FIG. 4A;

FIG. 5 is a view of the adapter placed in a wafer; FIG. 6A is across-sectional side view of the adapter with wire bonds;

FIG. 6B is a perspective view of FIG. 6A;

FIG. 7A is a cross-sectional side view of the adaptor receiving twocapacitor packages;

FIG. 7B is a circuit representation of the capacitor package connectionof FIG. 7A;

FIG. 8A is a cross-sectional side view of an adapter receiving twocapacitor packages in accordance with another embodiment of theinvention;

FIG. 8B is a circuit representation of the capacitor package connectionof FIG. 8A;

FIG. 9A is a perspective cross-sectional view of another embodiment ofthe invention shown connected in a connector wafer; and

FIG. 9B is a perspective view of the adapter of FIG. 9A;

FIG. 10A is a perspective cross-sectional view of another embodiment ofthe invention having tiered capacitors, and connected to traces on aboard;

FIG. 10B is a more detailed view of FIG. 10A;

FIG. 11A is a perspective cross-sectional side view of the adapterconnected to a signal conductor, without encapsulant;

FIG. 11B is a perspective view of the adapter of FIG. 11A withencapsulant;

FIG. 12 is a perspective view of another embodiment of the invention;and

FIG. 13 is a perspective view of another embodiment of the inventionmounted vertically.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In describing a preferred embodiment of the invention illustrated in thedrawings, specific terminology will be resorted to for the sake ofclarity. However, the invention is not intended to be limited to thespecific terms so selected, and it is to be understood that eachspecific term includes all technical equivalents that operate in similarmanner to accomplish a similar purpose. Several preferred embodiments ofthe invention are described for illustrative purposes, it beingunderstood that the invention may be embodied in other forms notspecifically shown in the drawings.

Turning to the drawings, FIG. 3A is a cross sectional view of an adapter100 according to an exemplary embodiment of the present invention. Theadapter 100 is especially designed for use with the smaller package 5.The capacitor adapter 100 includes electrically conductive contactmembers 160 and an electrically insulative housing 110. The housing 110can have a rectangular shape that generally corresponds to the shape ofthe package 5. Accordingly in the embodiment shown, the housing 110 hasfour outer circumferential walls 112 formed by two longitudinal sidewalls and two transverse end walls, which together define an interiorspace 130. The adapter 100 includes an upper section 132 and a lowersection 134. The package 5 is received in the interior space 130 at theupper section 132. The bottom and top of the housing are open, thoughthe housing 110 can optionally be filled with the encapsulant or pottingfilling compound 190.

The outer circumferential wall 112 includes an optional interior shelf114 that projects inwardly and separates a top portion and a middleportion of the encapsulant 190. The shelf 114 helps support theencapsulant 190 and prevent it from escaping the interior space 130during its cure cycle. End support members 116 are formed at the lowersection 134 of the housing 110. The support members 116 are formed atthe shorter lateral ends of the housing 110, and have a straightinwardly-facing side and curved outwardly-facing sides.

Each of the contact members 160 has opposite ends and is bent to formshorter legs 166, 167, curved portions 164, and longer legs 162, 163.Each of the curved sections 164 has a 180-degree turn to form a U-shape,such that the longer legs 162, 163 are substantially parallel to each ofthe shorter legs 166, 167 and each of the contact members 160 generallyforms a “J” shape. The longer legs 162, 163 of the contact member areconfigured to electrically connect with an electrical component. Forexample, each of the longer legs 162, 163 can be electrically connectedto the end members 12 ₁, 12 ₂ of the package 5. The shorter legs 166,167 of the contact member 160 are configured to electrically connectwith a printed circuit board or connector. For example, each of theshorter legs 166, 167 can be electrically connected to the conductorleads 24 a, 24 b illustrated in FIGS. 2A, 2B.

Because the shorter legs 166, 167 are shorter than the longer legs 162,163, the longer leg 162, 163 extend further inward toward the center ofthe interior space 130 of the housing 110. Thus, there is a distance 172between the distal end 168 of the longer leg 162 and the distal end ofthe shorter leg 166. Accordingly, the contact portions of the shorterlegs 166, 167 are further apart than the contact portions of the longerlegs 162, 163. And as shown, the contact portions of the shorter legs166, 167 are further apart than the end members 12 ₁, 12 ₂ of thepackage 5. That is, the distal ends of the shorter legs 166, 167 areseparated by a distance that is greater than the length of the package5. As a result, the shorter legs 166, 167 are designed to connect withcontacts (such as conductor leads 24 a, 24 b) that the package 5 itselfis too small to connect with.

The longer legs 162, 163 are aligned with and co-planar with each other.The shorter legs 166, 167 are also aligned with and co-planar with eachother. And, the longer legs 162, 163 are parallel to the shorter legs166, 167. The longer and shorter legs 162, 163, 166, 167 can each beelongated. The longer legs 162, 163 do not touch each other, whereby agap 170 is formed between the distal ends 168 of the two longer legs162, 163. The shorter legs 166, 167 also do not touch each other, and agap is formed between the distal ends of the two shorter legs 166, 167.The contact members 160 can be formed from a single elongated thin pieceof metal. The ends can be bent to form the curved portion 164, and thegap 170 can be stamped.

The thickness of the contact member 160 (FIG. 3A) does not have the sameconstraints as the lead frame 24 of the wafer 20 (FIGS. 1-2), andtherefore the contact member 160 can be thinner (or thicker) than thelead frame 24 of the wafer 20. That is, the contact member 160 does notform out of the same base material as the lead 24. The base thickness ofthe lead 24 is tied to connector's desired properties. This allows thecontact member 160 to be gauged to desired properties, such that theadapter can have independent functions related to connector basematerials. Because the contact member 160 can be made thinner, a smallergap 170 can be formed in the contact member 160 than the gap 26 (FIG.1B) formed in the lead 24. In one example embodiment, typical conductor24 thickness is in the range of 0.20-0.30 mm and typical adapter basematerials for the contact 160 can range between foils of 0.05-0.10 mmthick. Because the gap 170 of the capacitor adapter 100 may be smallerthan the gap 26 of the wafer 20, the capacitor adapter 100 canaccommodate smaller packages 5 than packages that are directly connectedto the lead frame 24 of the wafer 20. For example, as shown in FIG. 3A,the capacitor adapter 100 is electrically connected to the smallerpackage 5 since the gap 170 is small enough for the smaller package 5 tospan the gap 170. The smaller package 5 may be, for example, a 0201-sizedevice, which is half the size of the larger 0402-size package 10illustrated in FIGS. 1-2.

The contact members 160 can include end support members 116. Each of theend support members 116 are formed between one of the longer legs 162,163 and the respective one of the shorter legs 166, 167, as well as twoof the respective outer circumferential walls 112 of the housing 110.The end walls 112 of the housing 110 have a slot 136 formed at the lowersection 134 of the adapter 110. An opening 138 is also provided at thebottom center of the end walls 112. The proximal end and top of thecurved portion 164 of the contact member 160 are positioned in the slot136 and opening 138 in the end walls 112 of the housing 110. The opening138 is optional and can be used to mold and stamp this area. Forinstance, the opening 138 allows exposed metal that can form a filletwhen soldered to the lead frame conductor 24. The fillets add strengthto the solder bond between the conductor 24 and the adapter conductor160, leading to improved long term package reliability and resistance toshock, environmental stress and strains due to thermal cycling in situand during press fit assembly.

FIG. 3B is a top-down view of the capacitor adapter 100 in accordancewith a non-limiting exemplary embodiment of the present invention. Thecapacitor adapter 100 is shown alongside a larger 0402-size package 10.As illustrated, the adapter 100 is substantially the same size and shapeas the conventional larger 0402-size package 10. The connector adapter100 is configured to receive a standard smaller 0201-size device 5.Because the capacitive adapter 100 occupies the same space as the larger0402-size package 10, the capacitor adapter 100 enables the smaller0201-size device 5 to electrically connect with the leads 24 a, 24 bthat are normally sized and spaced for the larger 0402-size package 10.That is, the gap 26 between the leads 24 a, 24 b is too large for thesmaller 0201-size device 5 to connect with the leads 24 a, 24 b.However, the shorter legs 166, 167 of the contact member 160 are furtherapart and can span the larger gap 26 between the leads 24 a, 24 b. Andthe longer legs 162, 163 of the contact member 160 are closer togetherso that the smaller package 5 can span the gap 170 between the longerlegs 162, 163.

The capacitor adapter 100 also provides mating surfaces that areconfigured to electrically connect to devices 5 of varying sizes eithersmaller or larger than the smaller packages 5 and/or the larger packages10. That is, the gap 170 between the longer legs 162, 163 can madelarger or smaller to accommodate different size packages 5, 10, or alarger package 10 can be utilized with a smaller gap 170. In addition,the adapter 100 can be made to fit in different size gaps. The shorterlegs 166, 167 can be separated further or closer together to mate withleads 23 a, 23 b that are further or closer apart.

Still referring to FIG. 3B, the size of the connector adapter 100 can bereduced by dimensions A+B because shorter legs 166, 167 (FIG. 3A) of areduced-size adapter 100 may be configured to electrically connect tothe leads 24 a, 24 b of the lead frame 24 illustrated in FIG. 2B. Asbest shown in FIGS. 3B, 3C, the capacitor adapter 100 includes a divider118 formed about midway down in the housing 110, which together with thelonger leg portion 163 of the contact member 160, defines the uppersection 132 and the lower section 134. The divider 118 extends inwardfrom the side outer walls 112 and joins with the support members 116 atthe lateral ends of the housing 110. In addition, a channel or recess120 is formed at the middle of the divider 118, and the longer legportion 163 is received in that recess 120. The contact member 160 canbe sufficiently rigid so that the longer leg portions 162, 163 cansupport the device 5.

FIG. 3C is a bottom-up view of the capacitor adapter 100 and the centerbody member 14 of a package 5, according to an exemplary embodiment ofthe present invention. The housing 110 includes two openings 138. Thecurved portions 164 of the contact members 160 are at the openings 138.Each of the shorter legs 166, 167 of the contact member 160 include acontact end 176 configured to electrically connect to a printed circuitboard (e.g., the leads 24 a, 24 b of the lead frame 24 illustrated inFIG. 2B). The contact ends 176 are wider than the curved portions 164,and the longer legs 162, 163. The contact ends 176 are elongated with alongitudinal axis substantially perpendicular to the longitudinal axisof the adapter housing 100 and a longitudinal axis of the longer legs162, 163. The contact ends 176 can extend the entire width of thehousing 110 to provide the greatest contact area and a reliableconnection to a mating contact. In addition, the contact ends 176 arebeneath the housing 110, so that they are the bottommost part of theadapter 100. Thus, the longer legs 162, 163 are at the interior space130 of the housing 110, while the contact ends 176 are external to thehousing 110. In this manner, the contact ends 176 (i.e., the contactportions of the shorter legs 166, 167) can come into contact with themating connector without any obstruction, and the housing 110 sits ontop of the shorter legs 166, 167. The contact ends 176 are flat andco-planar so that the adapter 100 is steady when positioned with respectto the mating connector. It should be recognized that other suitablealternatives are available. For instance, while the contact ends 176 arewider than the rest of the contact member 160, it need not be wider.Alternatively, the shorter legs 166, 167 may have a narrower sectionthat leads to a wider section.

The capacitor adapter 100 also includes a divider 118 formed aboutmidway down in the housing that, together with the long leg 162, 163 ofthe contact members 160, define the upper section 132 and the lowersection 134 of the housing 110. The divider 118 extends inward from theside outer walls 112 and joins with the support members 116 at thelateral ends of the housing 110. In addition, a channel or recess 120 isformed at the middle of the divider 118 above the support members 116,and a slot 136 and opening 138 are formed in the shorter transverse endwalls 112.

As best shown in FIG. 3C, the longer legs 162, 163 can each have awidened receiving portion 174 that curves or extends outward. Thatreceiving portion 174 receives and electrically connects with the bottomface 16 of the respective end terminals 12 of the package 10. Thewidened receiving portions 174 provides better target registration andensures a more reliable solder joint with the terminals 12 of thepackage 10. In addition, if the wafer 20 has fully or partially exposedair sections around the lead frame 24 (as opposed to a plastic-coveredmetal lead frame 24), the dielectric constant changes in that area whichleads to an unintended change in the impedance. The added metal in thewidened receiving portions 174 mitigates that impedance change. Thewidened receiving portions 174 can also be tuned to provide the desiredimpedance. In addition, the divider 118 and longer legs 162, 163 aresimilar in width, so that the top and bottom surfaces of the divider 118are uniform and flush with the top and bottom surfaces of the longerlegs 162, 163, respectively. An opening 122 can be provided in thedivider 118 at the gap 170 between the distal ends 168 of the longer leg162, 163.

While the contact ends 176 and portion of the shorter legs 166, 167 arepositioned at or on the bottom of the housing 110, the remainder of thecontact member 160 is received in the housing 110. The distal portion ofthe longer legs 162, 163 are positioned between the divider portions118, and the proximal portion of the long leg 162 is received within therecess 120 of the divider portion 118. The long leg 162 is supported bythe support member 116, and so can extend outward beyond the supportmember 116 into the space created between the two support members 116.

To construct the adapter 100, the contact 160 is provided as a singleelongated thin strip. The contact 160 is then bent to form the curvedportion 164 and legs. The housing 110 is then formed about the contact160 as a single integral molded member. The gap 170 in the contact 160can be stamped either before or after the molded housing is formed, bysupporting the longer legs 162, 163 from below and stamping the gap fromthe top. Once the housing 110 and contact member 160 are assembled, theconnector device 5 is placed on the exposed longer legs 162, 163 of thecontact member 160. The bottom face 16 of the component 5 can be adheredto the contact portion 163, such as by glue or solder. Thus, the bottomface 16 of each end terminal 12 comes into contact and electricalcommunication with a respective one of the longer legs 162, 163 of thecontact member 160. The center body member 14 of the device 5 extendsacross the gap 170. Once the package 5 is bonded to the longer legs 162,163, the encapsulant 190 is added, and the shorter legs 166, 167 arethen bonded to the wafer/connector.

The upper section 132 of the interior space 130 of the housing 110 isthen optionally filled with an encapsulant 190. The encapsulant 190 issufficiently viscose so that it does not escape through the opening 170.The encapsulant 190 binds to the interior surface of the outercircumferential walls 112, as well as the shelf 114, and the packagingdevice 5, thereby fixing the packaging device 5 in position on thecontact member 160 and sealing the component 5 within the housing 110.The encapsulant 190 fills the entire upper section 132 of the interiorspace 130. The housing 110 and encapsulant 190 are formed of aninsulative material, so as to not interfere with operation of the device5. The encapsulant 190 can be a liquid epoxy or other suitable material,and can be UV cured from the top and/or bottom of the housing 110.

Accordingly, the connector adapter 100 of FIGS. 3A-3C is configured toconnect a smaller 0201-size device 5 to the mating contacts that aresized to accept a larger 0402-size device. More specifically, the0201-size package 5 is positioned on the first contact portion at theupper (upward-facing) surface of the longer leg 163 of the contactmember 160, which is at the upper section 132 of the housing 110. Thesecond contact portions at the lower (downward-facing) surface of theshorter leg 167 of the contact member 160 are positioned wider apartthan the first contact portions 163, and are configured to connect withmating contacts of a connector that are sized to accept a larger0402-size package. Thus, the smaller 0201-size package 5 is inelectrical communication with the mating contacts of the matingconnector. Using a smaller package 5 adds new abilities to tuneconnector impedance around the device and improve device placementopportunities in the connector. Using smaller capacitor bodies, such asthe 0201-size package 5, reduces the metal, ceramic and air disturbancesassociated with the capacitor and enables the use of capacitors in areasthat cannot accommodate a larger capacitor. The configuration can alsobe made smaller with -01005 capacitor bodies.

FIGS. 4A-4C illustrate a dual package adapter 200, according to anotherexemplary embodiment of the present invention. Referring to FIG. 4A, thedual package adapter 200 includes a housing 202 with first and secondpockets (or compartments) 210, 230. The housing 202 is substantiallyrectangular in shape and has opposite transverse end walls 204 andopposite longitudinal side walls. The compartments 210, 230 are locatedtoward each of the transverse end walls 204 and are separated by atransverse opening 220. The opening 220 is an elongated slot that islocated at the longitudinal center of the housing 202 and extendstransversely across the entire internal width of the housing 200, fromone longitudinal wall 204 to the opposite longitudinal wall. Thelongitudinal axis of the compartments 210, 230 and opening 220 aresubstantially parallel to each other and substantially perpendicular tothe longitudinal axis of the housing 202.

The opening 220 can be used to control the distance between the centerlongitudinal axes of the two components 210, 230, which allows theimpedance to be controlled. Though an opening 220 is shown, it should beappreciated that a solid member between the two compartments 210, 230can be provided or the two compartments 210, 230 can share a commonwall. For instance, the opening 220 can be filled with a dielectric tocontrol impedance of the adapter 200. Each of the compartments 210, 230can be filled with an encapsulant similar to the encapsulant 190 of FIG.3A.

FIGS. 4B, 4C illustrate the dual package adapter 200 of FIG. 4A withoutencapsulant. Here, each of the compartments 210, 230 are substantiallysimilar to the adapter 100 of FIGS. 3A-3C. In other words, the dualpackage adapter 200 effectively combines two adapters 100 in a singlehousing 202. For instance, the two compartments 210, 230 may eachcontain a 0201-size package 5 and contacts that connect the package 5 tolarger mating contacts at the outside of the housing 202. FIG. 4C is abottom-up view of the dual package adapter 200 of FIGS. 4A-4B. The dualpackage adapter 200 includes elongated contacts 212, 214 of one package5 parallel to and/or linear with respective contacts 232, 234 of anotherpackage 5.

As shown in FIG. 4B, the dual package adapter 200 enables two smallerpackages 5 to be placed in parallel. For example, each of the packages 5may electrically connect one signal contact in a differential pair. Thedual package adapter 200 reduces electrical interference between the twopackages 5 and reduces mold flow issues which may arise if the twopackages 5 are placed in a single housing chamber. The dual packageadapter 200 provides a path to reduce volume by allowing smallercompartments 210 and 230 to be used, which reduced impedance changes andprovides an increased distance between the two devices 5. In addition,the smaller profile enables smaller impedance variation, which isparticularly advantageous at higher speeds. As will be apparent, thehousing 202 can be configured to accommodate more than two packages 5,and the packages can be arranged in serial fashion rather than inparallel.

FIG. 5 illustrates the capacitor adapter 100 of FIGS. 3A-3C incorporatedwithin the wafer 20 of FIGS. 1A, 2A, 2B, according to an exemplaryembodiment of the present invention. The wafer 20 includes a standard0402-size component 10 in the upper left opening 22 and the adapter 100in the lower right opening 22. The adapter 100 enables a smallercomponent 5 (for example, a 0201-size component) to bridge a gap 26between the conductors 24 a, 24 b and electrically connect the smallercomponent 5 to the conductor 24 of the lead frame. As illustrated inFIGS. 3A-3C, the shorter legs 166, 167 of the adapter 100 are separatedby a distance that is greater than the length of the component 5, andenable the 0201-size component 5 to electrically connect with theconductors 24. The 0201-size component 5 by itself is not large enoughto span the gap 26. However, the longer legs 162, 163 are closertogether, such that the component is able to span the gap 170, while theshorter legs 166, 167 are further apart and can connect with theconductors 24 a, 24 b. Thus, the 0201-size component 5 electricallyconnects with the conductors 24.

FIGS. 6A, 6B show an adapter 300 according to another exemplaryembodiment of the present invention. Here, the adapter 300 is the sameas the adapter 100 of FIGS. 3A-3C, with the addition of wire bonding302, which is optional. The component 5 is affixed to the contactportion 163 by the wire bonding 302. The wire bond 302 has a straightsection and a curved section at the top of the straight section, togenerally form an inverted J-shape. The wire bond 302 is a thinelongated round wire that extends upward from the top surface of theconductive member 160 outside of the component device 5. It has a firstend that connects with the top surface of the long leg 162, 163 and asecond end opposite the first end that connects with the top surface 13of the end terminal 12 of the package 5. The housing of the adapter 100can optionally be filled with encapsulant, and the device 5 can besoldered or adhered to the longer legs 162, 163.

FIG. 7A shows the adapter 400 according to another exemplary embodimentof the present invention. Here, the adapter 400 includes dual capacitordevices 5, 7 to illustrate the connection of multiple devices 5, 7 in astacked or tiered configuration. An upper 0201-sized device 5 isprovided at the upper section 432, and a lower 0201-sized device 7 isprovided at the lower section 434. Thus, the upper and lower devices 5,7 are vertically aligned, so that the central longitudinal axes of thedevices 5, 7 are parallel with one another. Though two devices 5, 7 areshown, more devices 5, 7 can be connected.

In the current embodiment, the lower section 434 is enlarged to fit thelower device 7 by extending the curved portions 464 of the contactmember 460, as shown. The support member 416 can also be enlarged toextend between the longer legs 462, 463 and shorter legs 466, 467,and/or a shelf 469 can be provided. The lower device 7 does not extendoutside of the housing 410, so that the shorter legs 466, 467 remain thelowest part of the adapter 100.

The lower device 7 can be soldered or glued to the bottom (i.e.,downward-facing in the embodiment shown) surface of the longer legs 462,463. The top or bottom faces 13, 16 of the end terminals 12 can beconnected to top (i.e., upward-facing) surface of the contact portion463. Bonding wires 302 (such as shown in FIG. 6B) or printed leads canalso be provided for each of the upper and lower devices 5. Although thedevices 5, 7 are shown aligned with one another vertically andsubstantially parallel, they can be offset with respect to one anotherand need not be substantially parallel.

When the two capacitor devices 5, 7 are connected in the manner shown inFIG. 7A, they are connected in a parallel relationship, as representedby the circuit diagram of FIG. 7B. Accordingly, the total capacitance isthe sum of the capacitance of the two capacitor devices 5, 7, orC_(total)=C₁+C₂+ . . . C_(n). This enables smaller adapters to exhibitmore capacitance, so that smaller value capacitor devices 5, 7 can beused. For example, 100 pFarads can be provided by placing two 50 pfcapacitor devices (01005-size, which is smaller than a 0201 component)in parallel with one another. It should further be appreciated that theadapters 100 and/or 400 can be further stacked on top of one anotherwith the devices 5, 7 connected between the two adapters 100, 400, toprovide further capacitors in parallel with one another. Any number ofadapters 100, 400 can be stacked, though preferably within the thicknessof the wafer 20 to which the adapters 100, 400 are connected. One suchembodiment is shown in FIGS. 10A, 10B.

FIG. 8A shows a dual capacitor adapter 450 according to anotherexemplary non-limiting embodiment of the present invention. Here, thedevices 5, 7 are arranged in a serial fashion or end-to-end relationshipsuch that the end face 18 ₁ of the end terminal 12 ₁ of the first device5 faces the end face 18 ₂ of the end terminal 12 ₂ of the second device7. The longitudinal walls 112 of the housing 110 are extended toaccommodate the two devices 5, 7, and the two longer legs 163 ₁, 163 ₂are separated by a larger gap 170. A central contact member 180 isprovided at the center of the housing 110. The central contact member180 is flat and can have the same thickness as the longer legs 163 ₁,163 ₂, and has a first contact end 182 and a second contact end 184opposite the first contact end. The central contact member 180 can besupported, for instance, by the side walls of the housing, whereby theside walls can be molded about the central contact member 180. The firstpackage 5 has a first end that connects to the first longer leg 163 ₁and a second end that connects to the first contact end 182 of thecentral contact member 180. The second package 7 has a first end thatconnects to the second contact end 184 of the central contract member180 and to the second longer leg 163 ₂.

Accordingly, with respect to the first device 5, the bottom surface 16of the first end terminal 12 ₁ connects with the first longer leg 163 ₁at the left side of the illustrated embodiment. And the bottom surface16 of the second end terminal 12 ₂ connects with the first contact end182 of the central contact member 180. With respect to the second device7, the bottom surface 16 of the first end terminal 12 ₁ connects withthe second contact end 184 of the central contact member 180. And thebottom surface 16 of the second of the second end terminal 12 ₂ connectswith the longer leg 163 ₂ at the right side of the illustratedembodiment. The dual capacitor adapter 400 provides an in-seriesconnection from a connector 24 a of a wafer 20 (such as the one in FIG.2A), through the longer leg 163 ₁, then through the first device 5, thenthrough the central contact member 180, then through the second device7, then through the longer leg 163 ₂, and to the lead 24 b. Though notshown, the present embodiment can be combined with features of theearlier embodiments of FIGS. 3-7. For instance, two additional devices5, 7 can be provided at the lower section 134 of the housing andconnected to the contact members 163, 180, as in the manner shown inFIG. 7A.

When the capacitor devices 5, 7 are connected as shown in FIG. 8A, theyare connected in series as represented by the circuit diagram of FIG.8B. The total capacitance is then represented as

$\frac{1}{C} = {\frac{1}{C\; 1} + {\frac{1}{C\; 2}.}}$

Thus, FIGS. 8A, 8B show an adapter 450 with multiple devices 5, 7arranged in a linear fashion. Though two devices 5, 7 are shown, anysuitable number of devices can be connected, such as by providingadditional central contact members 180. Those central contact memberscan further connect the packages 5, 7 in other suitable configurations.

Turning to FIGS. 9A, 9B, a dual capacitor adapter 500 is shown accordingto another exemplary non-limiting embodiment of the present invention.The adapter 500 is configured to be connected in the gap 26 (such as theone shown in FIG. 2A) provided between two contact portions 25 ₁, 25 ₂of a signal conductor. Here, the adapter includes a housing 510,elongated contact members 520, and optional encapsulant. Each of thecontact members 520 are a thin elongated member having a longer leg 522,a bend portion 524 and a shorter leg 526. The longer leg 522 extendsbelow the housing 510 and connects with the device 5, and also supportsthe device 5. The longer legs 522 do not meet each other, but instead agap 528 is formed between the distal ends of the two longer legs 522.The longer leg 522 and the shorter leg 526 are substantially straight.The bend portion 524 connects the two legs 522, 526 and forms an S-shapeso that the long leg 522 and the shorter leg 526 are substantiallyparallel to each other and offset by the bend portion 524. The shorterlegs 526 connect the adapter 500 to the contact portions 25 ₁, 25 ₂. Theshorter leg 526 is higher up than the longer leg 522, so that theprofile of the adapter 500 is minimized. The length of the bend portion524 is about one-half of the height of the device 5, so that the device5 is substantially vertically centered with respect to the conductors 25₁, 25 ₂. That is, the conductors 25 ₁, 25 ₂ align with the housing 510at about the mid-point of the housing 510. This minimizes the profile ofthe adapter 500.

The shorter legs 526 can have a wider width than the longer leg 522 andbend portions 524 to ensure a reliable connection with the conductors251, 252. As best shown in FIG. 9B, the shorter legs 526 can have awidth that extends the entire width of the conductors 251, 252. Theshorter legs 522 of the contact member 520 can be soldered or otherwiseadhered to the conductors 25. The current embodiment essentiallyeliminates the lower section 134 of the housing 110 of FIG. 3, whichfurther reduces the profile of the adapter 500. In the currentembodiment of the invention, the shorter legs 526 extend upward andoutward with respect to the longer legs 522; whereas in FIG. 3 thelonger legs 162, 163 extend upward and inward with respect to theshorter legs 166, 167.

As further shown in FIG. 9B, the longer leg 522 of the contact member520 can be contained within the walls of the housing 510. A slot 512 isprovided in the transverse ends of the housing 510 that allows thecontact member 520 to exit to the exterior of the housing 510 andcontact the conductors 25. Thus, the shorter legs 526 extendlongitudinally out of the opposite transverse ends of the housing 510.The adapter 500 enables a small capacitive device 5 to connect with theconductors 25 ₁, 25 ₂ that are wider apart than the end terminals of thedevice 5. The contact members 520 provide a smaller gap 528 than the gap26 between the conductors 25 ₁, 25 ₂, and connect to the widerconductors 25 ₁, 25 ₂.

FIGS. 10A, 10B shows a capacitor adapter 600 according to anotherexemplary embodiment of the present invention. Referring to FIG. 10A,the adapter 600 can be utilized, for instance, to electrically connectthree packages 5 a, 5 b, 5 c with conductors such as two mounting pads23 a, 23 b of a printed circuit board. Turning to FIG. 10B, thecapacitor adapter 600 includes a housing 610, which is similar to thehousing 110 illustrated in FIGS. 3-8, and two sets of conductive members160 a, 160 b. The two conductive members 160 a, 160 b have a similarstructure and purpose to the conductive members 160 illustrated in FIGS.3-8, each with shorter legs 166 a, 167 a, 166 b, 167 b, and longer legs162 a, 163 a, 162 b, 163 b, respectively. The device 5 can be adhered(e.g., soldered) to the legs 522, and the short legs 526 can be adhered(e.g., welded) to the conductors, which for instance can be the leads 24a, 24 b (FIG. 2A) or the traces 23 a, 23 b (FIG. 10A).

The first conductive member 160 a is electrically connected to the firstand second devices 5 a, 5 b in a similar manner as illustrated in FIG.7A. The shorter legs 166 b, 167 b of the second conductive member 160 brest on and electrically connect with the longer legs 162 a, 163 a ofthe first conductive member 160 a, and the longer legs 162 b, 163 bconnect to the third device 10 c. The curved portion of the secondconductive member 160 b is long enough so that the second device 10 bdoes not touch the longer legs 162 b, 163 b of the second conductivemembers 160 b. When the three capacitor devices 5 a, 5 b, 5 c areconnected in the manner shown in FIG. 10B, they are connected in aparallel relationship. Accordingly, the total capacitance is the sum ofthe capacitance of the three capacitor devices 5 a, 5 b, 5 c, orCtotal=C1+C2+ . . . Cn. Encapsulant is provided at the top part of theinterior space of the housing 610 about the third package 10 c to sealthe entire housing 610, though encapsulant can optionally be providedabout the first and second packages 10 a, 10 b as well. In addition,while the second package 10 b is shown connected to the longer legs 162a, 163 a of the first conductive member 160 a, it can instead beconnected to the longer legs 162 b, 163 b of the second conductivemember 16 b. As further shown, the shorter legs 166 b, 167 b must bewider apart than the length of the second package 10 b. In analternative embodiment, the shorter legs 166 b, 167 b can be closertogether so that the second package 10 b rests on top of the shorterlegs 166 b, 167 b.

Though three devices 5 a, 5 b, 5 c are shown in FIG. 10B, additionaldevices can be provided in the vertically stacked or tieredconfiguration. In addition, one or more of the tiers can be expanded inthe horizontal direction, as in the embodiment of FIG. 8A. Thus, theadaptors can be configured to expand in two directions that areorthogonal to one another. The adaptors can be elongated to connectdevices in a serial fashion, as in FIG. 8A, and those adaptors can alsobe stacked with one another, as in FIGS. 7A, 10B.

As discussed and shown above, the adapters of FIGS. 3-10 electricallycan be utilized in a number of configurations. For instance, the adaptercan be used to connect a package or device 5, 10 to a conductor 24, 25(see FIGS. 5, 9A) of an electrical connector wafer (such as connectors20 ₁, 20 ₂ of FIG. 1A) or to mounting pads 23 a, 23 b on the surface ofa printed circuit board (such as boards 30, 40 and/or backplane board 50of FIG. 1A). For instance, the longer legs 162, 163 of the adaptersprovide a reliable contact surface for attachment of the devices 5, 10.The device 5, 10 can be adhered (such as by solder or the like) to thelonger legs 162, 163 and provide a reliable connection joint. And theshorter legs 166, 167 provide a reliable contact surface for attachmentof the adapter to a conductor 24, 25. The adapter can be adhered (suchas by solder or welding) to the conductors 24, 25 and provide a reliableconnection joint. The housing and encapsulant further protect the device5, 10 from electrical disturbances. And, the adapters are substantiallythe same width as the conductors 24, 25 to which they attach.

Another embodiment of the invention is shown in FIG. 11A. Here, theadapter 700 is connected to mounting pads 23 a, 23 b on the surface of aprinted circuit board (such as boards 30, 40 and/or 50 of FIG. 1A). Asshown, the tail 702 of a signal conductor extends downward and connectsto the mounting pad 23 a. The tail 702 is elongated and thin and has abend forming a foot 704, whereby the tail 702 has an L-shape with thetail 702 substantially orthogonal to the main body of the tail 702. Thebottom surface of the foot 704 is directly connected to the top surfaceof the conductive mounting pad 23 a. The foot 704 has a flat topsurface.

The adapter 700 is the same as the adapter 300 of FIGS. 6A, 6B above.However, a printed lead 701 is provided instead of a wire bond 302. Theprinted lead 701 can be generated, for instance, by Optomec Mfg.,www.optomec.com. Novel shapes and sizes can be created that do notrequire heat (i.e., solder and the associated reflow cycle to addressissues with lead free related heat cycle) that may warp or damageproperties of the connector or package adaptor that are heat sensitiveif desired. The bond strength of this approach is superior to adhesive.

In addition, the curved portion 764 ₂ is slightly elongated comparedwith the curved portion 764 ₁. The bottom surface of the shorter leg 766directly contacts the top surface of the foot 704 of the conductor tail702. Accordingly, the curved portion 764 ₂ is longer than the curvedportion 764 ₁ by a distance that equals the thickness of the foot 704(if the signal conductor mounting pad 23 a has the same thickness as thevia mounting pad 23 b), so that the adapter 700 remains level whenconnected with the mounting pads 23 a, 23 b.

Accordingly, current passes through the adapter 700 in the directionshown by the dashed arrows. The current comes in from the conductor tail702 to the mounting pad 23 a (the mounting pad 23 a provides a reliablecontact for the tail 702, but can be eliminated if desired) and theshorter leg 766. The current continues from the shorter leg 766, throughthe curved portion 764 ₁ to the longer leg. The current then passesthrough the capacitor package 5, and out through the longer leg andcurved portion 764 ₂. It continues through the shorter leg 767 to themounting pad 23 b and into the conductive via 4. For instance withrespect to FIG. 1A, the tail can be from either of the connectors 20 ₁,20 ₂, and the via 4 can be any of the vias 48 ₁, 48 ₂, 54 ₁, 54 ₂, 38 ₁,38 ₂, 52 ₁, 52 ₂. As best shown in FIG. 11B, the shorter legs 766, 767can be wider than the curved portions 764 ₁, 764 ₂, and extendsubstantially the entire width of the tail foot 704 and mounting pad 23b respectively, to which they are connected.

Thus, the adapter 700 enables the capacitor 5 to share the same via 4 asthe signal conductor tail 702. The adapter 700 directly contacts thesignal conductor tail 702, thus conserving space on the board 30, 40, 50while providing a reliable contact between the capacitor 5 and thesignal conductor tail 702. The curved portion 764 ₂ is longer than thecurved portion 764 ₁ so that the package 700 remains substantiallyhorizontal when connected to the tail 702 and mounting pad 23 b, asshown. However, the package 700 need not be horizontal, or otherconfigurations can be provided to keep the package horizontal withouthaving the curved portion 764 ₂ be longer than the curved portion 764 ₁.

As further shown in FIG. 11B, the opening 738 in the side wall 712 ofthe housing 710 can be enlarged to provide additional ways to mold andstamp this area. For instance, the opening 138 allows exposed metal thatwill form a fillet when soldered to lead frame conductor 24. The filletsadd strength to the solder bond between conductor 24 and adapterconductor 160, leading to improved long term package reliability andresistance to shock, environmental stress and strains due to thermalcycling in situ and during press fit assembly. And encapsulant can beprovided at the interior space of the housing 710.

FIG. 12 illustrates an adapter 800 according to another exemplaryembodiment of the present invention. Two adapters 800 are shown, eachconnected to a respective signal conductor tail 802, which can beutilized for instance to form a differential pair. It is noted that inFIG. 11A, the mounting pad 23 b extends away from the adapter 700;whereas in FIG. 12, the mounting pad 23 b extends beneath the adapter800 so that the via is located beneath the adapter 800. This allowsadditional space to be conserved on the substrate 31 (which can be anyof boards 30, 40, 50 of FIG. 1A, for instance).

As further shown in FIG. 12, a pierce tab mount through lead isprovided. Accordingly, one of the contact members 860 ₁ is a straightelongated member that does not have any curved portion. The straightcontact member 860 ₁ extends from the interior of the adapter housing810 straight out of the transverse side wall 812 of the housing 810through a correspondingly-shaped and sized opening in the side wall 812.The straight contact member 860 ₁ has a longitudinal axis that isparallel to the longitudinal axis of the package housing 810. Inaddition, the signal conductor tail 802 has a central opening 806 with adownwardly extending mating projection or tab 808 that extendsdownwardly (in the embodiment shown) from the top of the opening 806.The opening 806 is aligned with the straight contact member 860 ₁.

During assembly, the adapter 700 is angled with an opening in the distalend of the straight contact member 860 ₁ aligned with the tab 808. Thedistal end portion 868 of the straight contact member 860 ₁ extendsslightly through the opening 806, so that the mating tab 808 engages thedistal end portion of the straight contact member 860 ₁. The straightcontact member 860 goes directly through the conductor tail 802 toprovide direct mechanical attachment to the lead frame. Solder can befilled in after a solder attach cycle to provide superior strength ofbond or just another method to get the capacitor adaptor into thefootprint of the PCB board launch area. The adapter 700 is then loweredto be level with the top surface of the substrate 31, and so the curvedcontact member 860 ₂ comes into contact with the mounting pad 23 b. Thestraight contact member 860 ₁ can rest on the bottom edge or surface ofthe opening 806 of the tail 802 for support. The contact member 860 ₁can then be soldered or adhered into position in connection with the tab808.

The other adapter contact member 860 ₂ can have a curved portion anddirectly couple the mounting pad 23 b, as in FIG. 11. Current flows fromthe signal conductor tail 802, through the contact member 860 ₁, throughthe capacitor, and along the contact member 860 ₂ to the mounting pad 23b and related via. Thus, the signal conductor 802 shares the same via asthe capacitor. This does not significantly change the transmission athigh frequencies, while blocking DC.

FIG. 13 illustrates an adapter 900 according to another exemplaryembodiment of the present invention. The adapter 900 is the same as inFIG. 3A, but the contact members 960 ₁, 960 ₂ are configured to couplewith a signal conductor 902 that is at an angle. More specifically, thesignal conductor has a proximal portion 903 that extends toward the topsurface of the substrate 31, but at an angle to the substrate 31. Theproximal portion also extends from the connector housing 901 at anangle. The signal conductor 902 also has a distal portion that isconfigured to form a general U-shape with two upturned sides 905, 906and a bottom portion 904. That shape supports the capacitor adaptor byadding mounting strength and stiffening the overall attach zone toresist stress and strain during actual use. For instance, one contact966 ₁, 966 ₂ can be thinner and less stiff (as shown) than the distalportion so that side is flexible, which in turn protects the adaptorhousing and contents. The lead side wall 904 carries the mechanicalload, and the capacitor contact legs 966 ₁-966 ₂ carry the electricalsignal. The housing 910 of the capacitor package 900 substantially fitsbetween the two sides 905, 906 and can rest on the top surface of theside 906. The side 904 forms a foot for the signal conductor 902 andcontacts the mounting pad 23 b.

The first contact member 960 ₁ has a curved portion that curves downwardand outward. Accordingly, the shorter leg 966 ₁ extends outward from theadapter housing 910 (instead of inward and under the housing 110 as inFIG. 3A). The shorter leg 966 ₁ of the first contact member 960 ₁ restsagainst the top surface of the angled distal portion 903 of the signalconductor 902, as shown. The shorter leg 966 ₁ can be relatively rigid,so that it exerts a pressure on the distal portion 903 to provide areliable contact. The shorter leg 966 ₁ can be uniform in width.

The shorter leg 966 ₂ of the second contact member 960 ₂ can be turnedoutward from the bottom surface of the housing 910, to be substantiallyparallel to the side 912 (i.e., substrate 31 in the embodiment of FIG.13) of the housing 910 and substantially parallel to the top surface ofthe substrate 31 and the mounting pad 23 a. The shorter leg 966 ₂ can becurved slightly outward from the housing 910 as well. The shorter leg966 ₂ can have a wide head that is substantially extends the entirewidth of the mounting pad 23 a. The upper and lower signal conductors902 (in the embodiment shown) are the same, but the signal conductorsare reversed. That is, the upper signal conductor 902 faces in onedirection so that the conductor 902 is on one side of the package 5, andthe lower signal conductor 902 faces in an opposite direction so thatthe conductor 902 is on the opposite side of the package 5.

FIGS. 11-13 illustrate that the adapter contact members can have anysuitable configuration and mate with signal conductors in differentways, and that both of the contact members need not have the sameconfiguration. For instance, contact members extend different distancesaway from the housing (FIG. 11); contact members can be straight orcurved (FIG. 12); contact members can rest on the foot of a signalconductor tail (FIGS. 11, 12); contact members can extend into anopening in the signal conductor tail (FIG. 12); contact members canextend outward from a bottom of the side wall (FIG. 13); and/or contactmembers can extend parallel to the side wall (FIG. 13). The invention isnot limited by the illustrated embodiments of the invention. FIGS. 11-13provide additional techniques that provide a more robust attach.

As noted, the adapters are especially designed for use with the packages5, 10, and have particular utility with the wafer of FIG. 2A. However,it will be apparent that the adapters can be utilized with other circuitelements having different sizes, shapes and configurations, and can beutilized in other connectors, and not with the specific packages 5, 10shown. In addition, while a single package 5 is shown connected to thetop surface of the longer legs 162, 163 in FIG. 3, it can instead beconnected to the bottom surface of the longer legs 162, 163.

As further noted, the smaller legs 166, 167 have flat bottom surfacesthat directly contact the surface to be mated with and form a reliableelectrical connection therewith. However, other configurations can beprovided. For instance, the bottom surface need not be flat, but canhave a projection that forms a contact point that mates with a flatsurface. Or, the smaller leg can form a pressfit or other connectionthat mates with a respective contact.

The figures and description are provided to illustrate the invention asbeing and adapter configured to respectively connect two contacts of anelectronic component to two target contact surfaces that are wider apartthan the length of the component. The adapter provides a first set oftwo contacts (such as an upper contact and a lower contact) and a secondset of two contacts (such as upper contact and a lower contact). The twolower contacts can be separated from each other by a first distance thataligns with the target contact surfaces. The two upper contacts can beseparated from each other by a second distance smaller than the firstdistance, so that the upper contacts are aligned with the contacts ofthe electronic component. The first set of upper and lower contacts canbe directly connected together, such as being formed from a sameelongated contact member that is bent toward one end to form a U-shape.And the second set of upper and lower contacts can be directly connectedtogether, such as being formed from another elongated contact memberthat is bent at one end to form a U-shape bend so that the upper andlower contacts are parallel to each other and the component is above thetarget contact surfaces.

It is noted that the invention has been described and shown as anadapter 100-900 (FIGS. 3-13) for use in a connector such as the wafer ofFIGS. 1A, 2A, 2B. It is further noted that the invention includes theconnector having leads or conductor elements (such as conductor elements24, 25 (FIGS. 1A, 9A) with the adapter 100-900 coupled to the conductorelements 24, 25.

In yet another embodiment of the invention, the adapters 100-900 ofFIGS. 3-13 protect the enclosed devices 5, 10 from environmentalconditions. So for instance, the entire adapter can be over moldedwithout damaging the device 5, 10. Accordingly, a wafer (such as thewafer 20 in FIGS. 1A, 2A, 2B) can be formed by (a) providing a leadframe having one or more elongated conductors, (b) forming gaps in theconductors 24 to provide conductor ends 24 a, 24 b, (c) placing one ofthe adapters 100-900 to span the gap and connect with the conductor ends24 a, 24 b, and then (d) over molding the entire lead frame (which wouldnot leave any openings 22 in the insulative over molding). The passivedevices 5, 10 cannot be directly over molded (in FIG. 2A) since the overmolding process involves high heat, high heat differentials and/or highpressures can develop in short periods of time (e.g., 11,000 psi in2/10ths of a second), and those pressures may not be uniformlydistributed. Those factors can destroy the device 5, 10 or otherwisecause the device 5, 10 to fail or become unstable or unreliable. Thus inthe earlier embodiments (e.g., FIG. 2A), the lead fame is over moldedfirst and then openings 22 are formed in the over molding 23 and thedevices 10 are placed therein.

However, the adapters 100-900 of the present invention containencapsulant and have a housing (such as housings 110, 510) so that thedevice 5, 10 is not directly exposed to the over molding and are notdestroyed during the over molding process. The encapsulant and/orhousing protect the device. The housing of the adapters 100-900 can havea bottom and top to fully enclose the circuit element 5, 10, or thebottom and top can be open (as shown) and encapsulant provided at thebottom and/or top to at least partially enclose the circuit element.

The encapsulation can be done with a needle that dispenses a liquidconformal coating that sits around the capacitor, or the capacitor canotherwise be submerged in the encapsulant. The capacitor encapsulant isthen exposed to UV light, which cures the encapsulant to make it hard bycross linking the polymers to create a solid. This process uses verylittle heat and little to no force is required. Accordingly, the passivedevice can be encapsulated without destroying the passive device. Theencapsulated passive device can then be coupled to the lead frame andthe lead frame with the encapsulated passive device can be over molded.The encapsulant protects the passive device from being destroyed duringthe over mold process.

In the current embodiment, the adapter can be a housing that encloses apackage 5, 10, conductors, and encapsulant. The conductors can extendfrom the package 5, 10 to outside the housing to couple with theconductive elements 24 a, 24 b, or 25. The housing is filled with anencapsulant to surround the package 5, 10 and protect the package 5, 10.The package 5, 10 can be large enough to span the gap 26 by itselfwithout the conductors having to extend outward beyond the package 5,10. Thus, the adapter need only encapsulate the package 5, 10 to protectthe package during over molding, and need not enlarge the footprint ofthe package 5, 10.

The foregoing description and drawings should be considered asillustrative only of the principles of the invention. The invention maybe configured in a variety of shapes and sizes and is not intended to belimited by the preferred embodiment. Numerous applications of theinvention will readily occur to those skilled in the art. Therefore, itis not desired to limit the invention to the specific examples disclosedor the exact construction and operation shown and described. Rather, allsuitable modifications and equivalents may be resorted to, fallingwithin the scope of the invention.

1. An adapter comprising: a housing defining an interior space; a firstand second flat elongated contact members fixed to the housing, eachhaving a first end configured to mate with two respective contacts of afirst electronic component whereby the first ends are co-linear andaligned with each other and separated from each other by a first gap;and said first and second contact members each having a second endconfigured to mate with two respective contacts of a second electroniccomponent whereby the second ends are co-linear and aligned with eachother and separated from each other by a second gap.
 2. The adapter ofclaim 1, wherein the second gap is wider than the first gap.
 3. Theadapter of claim 1, wherein said first and second contact members eachhave a curved section located between the first end and the second end.4. The adapter of claim 3, wherein said curved section forms a U-shapewhereby the second ends are substantially parallel to the first ends andbelow said housing.
 5. The adapter of claim 3, wherein said housingcomprises two lateral end walls and two longitudinal side walls and saidcurved section forms an S-shape whereby the second ends aresubstantially parallel to the first ends and extend outward from thelateral end walls.
 6. The adapter of claim 3, wherein the curved sectionis within the interior space of said housing.
 7. The adapter of claim 1,further comprising said first electronic component.
 8. The adapter ofclaim 1, further comprising encapsulant filling at least a portion ofthe interior space.
 9. The adapter of claim 1, wherein said housingcomprises two lateral end walls and two longitudinal side walls.
 10. Anadapter comprising: a housing defining an interior space; a firstcontact member having a first end with a first contact surface and asecond end having a second contact surface; a second contact memberhaving a first end with a first contact surface and a second end havinga second contact surface; wherein the first end of said first and secondcontact members are located within the interior space of said housing,and the second end of said first and second contact members are locatedoutside the interior space of said housing; wherein the first contactsurfaces of said first and second contact members are co-linear, alignedwith and spaced apart from each other by a first distance, and thesecond contact surfaces of said first and second contact members areco-linear, aligned with and spaced apart from each other by a seconddistance.
 11. The adapter of claim 10, wherein the second distance isgreater than the first distance.
 12. The adapter of claim 10, whereinsaid first and second contact members each have a curved section locatedbetween the first end and the second end.
 13. The adapter of claim 12,wherein said curved section forms a U-shape whereby the second ends aresubstantially parallel to the first ends and below said housing.
 14. Theadapter of claim 12, wherein said housing comprises two lateral endwalls and two longitudinal side walls and said curved section forms anS-shape whereby the second ends are substantially parallel to the firstends and extend outward from the lateral end walls.
 15. The adapter ofclaim 12, wherein the curved section is within the interior space ofsaid housing.
 16. The adapter of claim 10, further comprising said firstelectronic component.
 17. The adapter of claim 10, further comprisingencapsulant filling at least a portion of the interior space.
 18. Theadapter of claim 10, wherein said housing comprises two lateral endwalls and two longitudinal side walls.
 19. An adapter comprising: afirst elongated conductor having a U-shaped bend forming a shorter legportion and a longer leg portion; and a second elongated conductorhaving a U-shaped bend forming a shorter leg portion and a longer legportion, wherein said second elongated conductor faces said firstelongated conductor such that the longer leg portion of said secondelongated conductor is linearly aligned with the longer leg portion ofsaid first elongated conductor and the shorter leg portion of saidsecond elongated conductor is linearly aligned with the shorter legportion of said first elongated conductor.
 20. The adapter of claim 19,further comprising a first gap between the longer leg portions and asecond gap between the shorter leg, portions, wherein the first gap issubstantially smaller than the second gap.
 21. The adapter of claim 19,further comprising an electrical device having a first end connected tothe longer lea portion of said first elongated conductor, and a secondend connected to the longer leg portion of said second elongatedconductor. 22-38. (canceled)
 39. An electrical connector comprising: asignal conductor having a first conductor segment and a second conductorsegment separated from the first segment to form a gap therebetween; anadapter comprising: a housing defining an interior space; a firstcontact member having a first end with a first contact surface and asecond end having a second contact surface; a second contact memberhaving a first end with a first contact surface and a second end havinga second contact surface; a circuit element located within the interiorspace of said housing; wherein the first end of said first and secondcontact members are connected with the circuit element; and wherein thesecond end of said first and second contact members extend outside thehousing and connect with the first conductor segment and the secondconductor segment, respectively. 40-41. (canceled)